sample report kiln alignment

8/13/2019 Sample Report Kiln Alignment

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Sample Factory

Rotary Kiln #1 Hot Kiln Alignment

18-23 March 2012

ROTARY KILN SERVICES - TYRE, ROLLER THRUST ROLLER ON SITE MACHINING AND GRINDING - HOT KILN ALIGNMENT

BOSB Birlik Sanayi Sitesi 5. Cadde No:32 34520 Beylikduzu Istanbul TURKEY Phone: +90212 879 23 29 Fax: +90212 861 53 02 E-Mail: [email protected]

www.rotarykiln.eu


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Sample FactoryPage

1www.rotarykiln.eu

2346

ForewordDescription of MeasurementsWritten ReportBasic Inspection

789

101112

Coordinating System, Symbol and TermsAxial DeviationsSlope of Axis, Tyre and RollersSuggested AlignmentShell Heat MapRoller Bed Temperatures

13141516171819

Under-tyre Gaps and Relative MovementsTyre and Roller MovementsRoller Operating AnglesRoller Skew PositionsRoller Shaft ConditionsRoller and Shaft Positions and LubricationRoller Surface Wear

20212223

WobblingOvalityShell DeformationShell Sections

Rotary Kiln #1 Hot Kiln Alignment18-23 March 2012


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Page2

FOREWORD

As a main component of today's cement factories; rotary kilns have became an expensive-to-stop unit because of the increasingdemand, competition and production continuity policy. However, rotary kilns are mainly made of steel and work in hot conditionswhich deforms the initial design of the kiln. By the help of technological improvements, many variables of rotary kilns can beobserved and some other important variables should be observed by alignment professionals for an on-time intervention and bettermaintenance.

Rotary kiln alignment reports mean a technical photo of the rotary kilns which work on the presicion stability condiditons and thesereports help to undertand and solve the problems when it is resolvable by preventive maintenance.

Ozek Makina improves its rotary kiln service experience with technological add-ons and presents presicion hot kiln alignmentservices and targets to provide clean, easy and understandable reports.

We believe, the main saving for the rotary kiln is having an annual kiln analyse which helps for a better preventive maintenance anddurable working life.

Best Regards,

Ali ZEKMustafa ZEK

Zeki ZEK

Sample Factorywww.rotarykiln.euRotary Kiln #1 Hot Kiln Alignment

18-23 March 2012


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Page3

SCOPE

KILN

Basic inspection of working conditions.Establishing the coordinate system.Determining the horizontal and vertical axis deviations.

PIERS

Determining the roller skews and axial movement.Measuring the roller and tyre diameters.* Determining the concave, convex or conical wear.Calculating the roller working angles.

Determining the surface conditions of tyre and roller.Inspecting the roller bed lubrication efficiency.

Measuring the independent roller and tyre slopes.Measuring the tyre relative movement.Measuring the under-tyre gap.Measurement of tyre wobbling.

GEARS

Basic inspection of girth and pinion gears.Inspection of tooth condition.6 point backlash measurement.Lubrication efficiency.Individual slope measurement.Girth gear wobbling measurement.

SHELL

Measuring the shell deformation.Calculation of shell run-out and eccentricity.Measurement of shell and roller bed temperatures.Design of the shell deformation map.

Analyse of measurements.Preparing of the report.Presentation of report.

ALIGNMENT SUPERVISION


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ALIGNMENT

4 rollers are carrying the kiln up and 2 rollers are carrying it down. It isrecommended to increase the contact surfaces of middle pier rollersand tyre if necessary.

No eccentricity is observed on shaft miles. Discharge rollers haveeliptical wear and causes unequal load distribution.

Roller beds are in good condition and good lubrication efficiencyexcept feed pier mill side roller feed side bed.

All roller diamaters are measured on 5 different points and wearproblems are observed in discharge rollers.

All tyre and girth gear wobbling conditions are measured and it isobesrved that the values are in tolerance.

GEARS

All teeth of girth and both pinion rollers are in good condition.Lubrication efficiency is acceptible. Backlash values are between 11-16 mm. Both side baclash values are equal.

There is high vibration and sound noise in motor area caused by thekiln crank and eccentrici ty.

SUGGESTIONS

Shell temperature should be kept stable.

Kiln should work in up and down positions in equal times.

Dry lubrication graphite blocks should be checked regularly.

Discharge seal should be maintained in first shut down.

All 1,5 mm movements on rollers takes the kiln center 1 mm down orup depending on the movement.

Measurement plates should be placed on roller beds before alignmentmovements.

Cracks on the tyre stop blocks of feed tyre should be maintained in firstshut down.

WRITTEN REPORT


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Page6

BASIC INSPECTION

Feed seal is in good condition.There are cracks on both rollers of feed pier whichcauses unequal load distribution and marks on tyre

surface.

Hydraulic thrust roller has a pressure between0 - 50 bars.

Shell surface has spots caused by brick problemsand build-up.

The teeth of girth gear and pinion are in goodcondition. Backlash is in 11-16 mm range.

Backlash measurements are same at both sides.

Discharge seal leaks clinker out which causes wearon roller and tyre surfaces of discharge pier.


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Page7

COORDINATING SYSTEM, SYMBOLS AND TERMS

1. Pier

2. Pier

3. Pier

Girth Gear

s

dy

dz

ds

c

Under tyre gap

Roller operating angleSlope

Horizontal axis deviation.

Vertical axis deviation

Roller skew

Backlash

Manhole line is starting point forall diametral measurements.

Office side


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Page8

AXIAL DEVIATIONS

X

Y

Z

4555 mm

+0 mm

+0 mm

X

Y

Z

0 mm

+0 mm

+0 mm

OfficeSide

MillSide X

Y

Z

2507 mm

+6 mm

+1 mm

The tolerance of axial deviation is 1,5 mm for this kiln.


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%3,5

%3,6

%3,6

%3,6

%3,9

%3,6

%3,7

4 mm shim

In tolerance

Out of tolerance

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SLOPE OF AXIS, TYRE AND ROLLERS

Tyre and roller slopes are alsomeasured by the slope sensorswhich is mounted on the sideso f ty res and ro l le rs du r ingrotation.

This helps us to double checkthe slope data and get betterresults.


18-23 March 2012

Slope differences between tyre and rollers causes conical wear on both surfaces and wear on shaft and bed because of unequal loads. Max 0,2 differenceaccepted in tolerance for this kiln. ( If it is 2 m between two alignment bolts, %0,1 difference means 2mm shim.)


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SUGGESTED ALIGNMENT

7,5 mm

4,5 mm


18-23 March 2012

It is suggested to align the pier by moving 0,5 mm every bed in order. (Numbers on beds show the order.) A bed should be moved Max. 2 mm a day.The move which takes the tyre center down should be choosen for start.


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100 C

200 C

300 C

400 C

500 C

600 C

Max

Min

358

214

MaxMin 356174

Max

Min

218

118Max

Min

218

110

Max

Min

244

132

Max

Min

232

134

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SHELL HEAT MAP


18-23 March 2012


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Page12

ROLLER BED TEMPERATURES

33 39 30 343833

30 37 32 353626


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Page13

UNDER-TYRE GAPS (UTG) AND RELATIVE MOVEMENT (RM)

UTG

RM

9

15

UTG

RM

8

15

UTG

RM

7

12


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Page14

TYRE AND ROLLER DIAMETER

1970 1973 1960

1975 1964 1976

56615669 5653


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Page15

ROLLER OPERATING ANGLES

Feed Pier Middle Pier Discharge Pier

5945' 5832' 6006'

Sample FactoryRotary Kiln #1 Hot Kiln Alignment

18-23 March 2012www.rotarykiln.eu

For an equal load distribution, it is expected to have 60 2 roller operating angles.


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ROLLER SKEW POSITIONS

+3mm

-2mm

+2mm

Middle PierFeed Pier Discharge Pier


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ROLLER SHAFT CONDITIONS


Max

0,1 + 0,0 mm

Max

0,4 + 3,9 mm

Max

0,1 + 0,0 mm

Max

0,1 + 0,0 mm

Max

0,2 + 0,6 mm

Max

0,1 + 0,0 mm

Shaft Ovality + Roller Ovality


18-23 March 2012

The deviation created by non-cylinder roller form and curvature shaft mile causes unequal loads on rollers, bed wear and unefficient lubrication.Deviation under 1 mm is acceptible.


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ROLLER AND SHAFT POSITIONS AND LUBRICATION


Shaft

Lubrication

Shaft

Lubrication

Shaft

Lubrication

Shaft

Lubrication

Shaft

Lubrication

Shaft

Lubrication

ShaftLubrication ShaftLubrication

ShaftLubrication

ShaftLubrication

ShaftLubrication

ShaftLubrication


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ROLLER SURFACE WEAR

0.0

-1.0

-1.0

-1.5

-1.0

-1.0

-0.5

-0.5

0.0

0.0


Page19Sample Factory

www.rotarykiln.euRotary Kiln #1 Hot Kiln Alignment

18-23 March 2012

The diametral difference in 5 different points. Machining the concave rollers does not effect the kiln axis.The rollers of feed and middle pier are machined and do not have diametral deviation.


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OVALITY

A

B

C

ORT

%0,32

%0,46

%0,34

%0,37

A

B

C

ORT

%0,32

%0,48

%0,42

%0,41

A

B

C

ORT

%0,14

%0,22

%0,18

%0,18

A

B

C

ORT

%0,15

%0,21

%0,20

%0,19

A

B

C

ORT

%0,32

%0,32

%0,40

%0,35

A

B

C

ORT

%0,42

%0,38

%0,39

%0,40


18-23 March 2012

The ovality tolerance for a 4,60 m diameter shell is %0,5. Rapid changes in ovality diagrams signs fractures and cracks on shell.


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SHELL DEFORMATION

1234567891011121315 141618 17192021222324252627282930313233343536373839404142434447 46 45

5

10

15

20

25

mm


18-23 March 2012

By measuring the shell deformation on 47 sections of the kiln shell; deformation, run out and rotation center are calculated to draw the shell deformation diagram. It is shown that;21-36, 5-10, 0-2 sections has bigger run out and eccentricity which causes crank on shell, wobbling and unequal load distribution on tyres and rollers. ( Run Out , Eccentricity )


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Looking from Discharge

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Section :

Deform ratio 1:1 , Manhole at down position.

2SHELL SECTIONS


18-23 March 2012

Rotation

Center

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